1) Which tools should I buy to open the thing up? Tarkan sells the plastic tool kit, the pry tool and the metal spudger, which of those works most effectively?
2) This is the first time I'll be attempting to open up an iPod Classic, and I have no clue what kind of damage I'll be doing to it. As such, should I also consider ordering a new back plate? I don't really care it says 160GB in the back when it's going to be 256GB, I just want it to not fall apart.
3) Is there anything else I need to buy?

YES, you need all the tools you can get. this is one of the hardest thing you will open. took me all my energy just to pry it open. what did it for me was, I used the thin metal part on an old floppy disk to open the classic. watch all the videos you can on how to open a classic as it will come in handy. I did this 'surgery' as you call it and mine has all the scratches you can imagine but I was able to replace my hdd. and (knock on wood) I now have a nice working classic except for all the scratches it took.

1) Which tools should I buy to open the thing up? Tarkan sells the plastic tool kit, the pry tool and the metal spudger, which of those works most effectively?
2) This is the first time I'll be attempting to open up an iPod Classic, and I have no clue what kind of damage I'll be doing to it. As such, should I also consider ordering a new back plate? I don't really care it says 160GB in the back when it's going to be 256GB, I just want it to not fall apart.
3) Is there anything else I need to buy?

Thanks in advance.

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I'd order a replacement front and back plate. This way, there's no pressure to crack it open and not damage the front or back plates, which you will almost certainly do your first time. Incidentally, this makes getting the thing open much easier as doing so with the stipulation that you don't scratch either part is damn near impossible, especially on your first go. Given that I always buy replacement fronts and backs, I just use a small thin flathead screwdriver to get them open; much like the kind iFixit (and many of the Chinese parts people) supply you and that works well; though it definitely takes practice to get good at. Just remember where the clips are and how they work. That will often help you get the thing open.

Check eBay for the parts; they're pretty much everywhere. There are quite a few places that sell the custom "128GB" and "256GB" plates and they look pretty great. Some of them will even print the correct serial number if you so desire.

Silver iPod classic fronts are easier to source as black ones came in two different colors (one from the 2007 era and one from the 2008 through discontinuation era); just be warned that there are two different colors for black.

One part that Tarkan and the others don't explicitly state that you should get, but that I'm finding that is a must is kapton tape as the SD card often slips out of his CF to SD adapter as does the CF to SD adapter itself from the 1.8" PATA to CF adapter. His stuff is otherwise very high quality stuff.

I'd order a replacement front and back plate. This way, there's no pressure to crack it open and not damage the front or back plates, which you will almost certainly do your first time. Incidentally, this makes getting the thing open much easier as doing so with the stipulation that you don't scratch either part is damn near impossible, especially on your first go. Given that I always buy replacement fronts and backs, I just use a small thin flathead screwdriver to get them open; much like the kind iFixit (and many of the Chinese parts people) supply you and that works well; though it definitely takes practice to get good at. Just remember where the clips are and how they work. That will often help you get the thing open.

Check eBay for the parts; they're pretty much everywhere. There are quite a few places that sell the custom "128GB" and "256GB" plates and they look pretty great. Some of them will even print the correct serial number if you so desire.

Silver iPod classic fronts are easier to source as black ones came in two different colors (one from the 2007 era and one from the 2008 through discontinuation era); just be warned that there are two different colors for black.

One part that Tarkan and the others don't explicitly state that you should get, but that I'm finding that is a must is kapton tape as the SD card often slips out of his CF to SD adapter as does the CF to SD adapter itself from the 1.8" PATA to CF adapter. His stuff is otherwise very high quality stuff.

I agree the front and back casing is a good idea as well. I bought the iPod Classic around two years ago used for $20, but the hard drive was busted and the back/front aren't in the best condition, so I'm hoping this project will be a completely new start.

With what you're saying, I'm not going to buy tools dedicated to opening the thing up - just going to use a screwdriver and the plastic tools that come with the casing. Does this sound right?

I agree the front and back casing is a good idea as well. I bought the iPod Classic around two years ago used for $20, but the hard drive was busted and the back/front aren't in the best condition, so I'm hoping this project will be a completely new start.

With what you're saying, I'm not going to buy tools dedicated to opening the thing up - just going to use a screwdriver and the plastic tools that come with the casing. Does this sound right?

How's the battery and casing looking, anything I'm missing?

Does any kapton tape work, and how do you use it?

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Your list is sound. I'd get a putty knife just in case; the technique I used took time to learn and there's no real easy way to impart that experience; similarly staring at YouTube videos doesn't do the procedure justice. So, while the little flathead works for me. Don't assume it'll immediately work for you in the same manner.

As for Kapton tape; it works like most other kinds of tape. Tape the PATA to CF adapter where it connects and tape the CF to SD adapter where the card goes in. The goal is for neither connection to become loose. Otherwise, you have an iPod with signs of a failed storage medium (which while not technically true is still functionally true).

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